Airflow Deflector For Vacuum Cleaner

ABSTRACT

A vacuum cleaner includes an intake tube through which air is passed. An airflow deflector is disposed in the intake tube. A deflection surface of the airflow deflector is disposed at an obtuse angle with respect to a longitudinal axis of the intake tube passing through the deflection surface. The airflow deflector improves airflow from the intake tube into the vacuum bag, thereby improving the effectiveness of the vacuum cleaner.

FIELD OF THE INVENTION

The present invention relates to an airflow deflector for a vacuum cleaner. More particularly, the present invention relates to an airflow deflector for a vacuum cleaner having a deflection surface to improve airflow from an intake tube into a vacuum bag. Still more particularly, the present invention relates to a removable upper handle for a vacuum cleaner having an airflow deflector to improve airflow from an intake tube into a vacuum bag.

BACKGROUND OF THE INVENTION

Flow-through motor-style vacuum cleaners generally include an outer housing. The housing may be a partly porous bag because the airflow is being pushed into the vacuum bag. The housing is closeable, and typically uses a zipper or other suitable fastening means to access a vacuum bag (or filter bag) housed therein for removal and replacement of the vacuum bag. The vacuum bag is typically a disposable bag that collects dust and dirt during operation of the vacuum cleaner, and is disposed of when full and replaced with a new bag.

Air, which carries the dust, dirt and other collected debris, is drawn into the vacuum cleaner through its base. The air is then drawn up through a tube connected to the base. The air is directed from the tube into the vacuum bag disposed within the outer housing. Typically, a wall is disposed within the tube substantially perpendicular to a longitudinal axis of the tube to cause the air to flow from the tube into the vacuum bag. However, such a wall creates turbulence in the tube, thereby decreasing the airflow through the tube. The decreased airflow causes reduced suction of the vacuum cleaner, which results in decreased cleaning effectiveness of the vacuum cleaner. Accordingly, a need exists for a vacuum cleaner having improved airflow from the tube into the vacuum bag.

SUMMARY OF THE INVENTION

An airflow deflector in accordance with exemplary embodiments of the present invention improves airflow from an intake tube to a debris collector of a vacuum cleaner. The airflow deflector directs the airflow from the intake tube to the vacuum bag. The airflow deflector has a deflection surface having an obtuse angle with respect to a longitudinal axis of the intake tube passing through the deflection surface. Accordingly, turbulence is reduced such that the suction of the vacuum cleaner remains substantially constant. Accordingly, the cleaning effectiveness of the vacuum cleaner is maintained.

As used in this application, the terms “front,” “rear,” “upper,” “lower,” “upwardly,” “downwardly,” and other orientational descriptors are intended to facilitate the description of the vacuum cleaner, and are not intended to limit the structure of the vacuum cleaner to any particular position or orientation.

Other objects, advantages, and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The above aspects and features of the present invention will be more apparent from the description for an exemplary embodiment of the present invention taken with reference to the accompanying drawings, in which:

FIG. 1 is an elevational view of an upright vacuum cleaner showing the airflow through an intake tube and into an outer housing;

FIG. 2 is an elevational view in partial cross section showing a deflecting portion within the intake tube;

FIG. 3 is an exploded elevational view of the intake tube and handle of FIG. 2;

FIG. 4 is perspective view of the handle with the deflecting portion of FIG. 3;

FIG. 5 is an enlarged view of the deflecting portion of FIG. 4;

FIG. 6 is a perspective view of a vacuum bag prior to being connected to the vacuum cleaner;

FIG. 7 is an enlarged elevational view in partial cross section of a substantially planar deflection surface; and

FIG. 8 is an enlarged elevational view in partial cross section of a curved deflection surface.

Throughout the drawings, like reference numerals will be understood to refer to like parts, components and structures.

DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT

As shown in FIGS. 1-8, an airflow deflector 41 for a vacuum cleaner 11, including dust/dirt collectors, improves airflow from an intake tube 31 to a debris collector, such as a vacuum bag 21, although any suitable debris collector may be used.

The vacuum cleaner 11 includes a housing 15 that receives the vacuum bag 21, as shown in FIG. 6. The housing 15 is preferably porous to allow air passing through the vacuum bag 21 to pass through the housing. The housing 15 has a first housing part 16 and a second housing part 17. The first housing part 16 is secured to the vacuum cleaner 11, as shown in FIGS. 1 and 6. The second housing part 17 is movably connected to the first housing part 16, such as with a hinge 12. The remaining portion of the second housing part 17 is connected to the first housing part 16 in any suitable manner, such as with a zipper, to enclose the vacuum bag 21 therein. The second housing part 17 is openable with respect to the first housing part 16, to facilitate installing and removing the vacuum bag 21.

The vacuum bag 21, such as that disclosed in copending U.S. patent application Ser. No. 12/628,840, which is hereby incorporated by reference in its entirety, includes a container portion 23 having an opening 24 therein, as shown in FIG. 6. Although shown as having a substantially rectangular shape, the vacuum bag 21 may have any suitable shape. The container portion 23 may be made of a flexible and porous material, such as paper, non-woven material, woven material, or a combination thereof. The container portion 23 has a front wall 25 and an opposite back wall 26. The opening 24 is formed in the front wall 25 of the container portion 23 for the intake of dust and debris from a vacuum cleaner. Preferably, the opening 24 is centered horizontally on the front wall 25 proximal an upper edge 27 of the container portion 23 to facilitate disposal in the vacuum cleaner housing 15. Alternatively, the opening 27 may be disposed in any suitable surface of the container portion 23. An attachment assembly 29 can be used to connect the vacuum bag 21 to the vacuum cleaner 11, such as is disclosed in copending U.S. patent application Ser. Nos. 13/074,846 and 61/491,782, both of which are hereby incorporated by reference in their entirety. The vacuum bag 21 is connected to a nozzle 36 of the intake tube 31 such that air from the intake tube is passed through the nozzle 36 into the vacuum bag 21.

A handle assembly 51 is connected to the intake tube 31, as shown in FIGS. 1 and 6. The handle assembly 51 is removably connectable to the intake tube 31, as shown in FIGS. 2 and 3. An opening 32 in the intake tube 31 receives a fastener 34 to secure an upper cord hook 33 to the intake tube 31. An electrical cord (not shown) to supply electrical power to the vacuum cleaner 11 can be wrapped around the upper and lower cord hooks 33 and 35 for convenient storage of the electrical cord. Additionally, the handle assembly 51 can be removed from the intake tube 31 to permit the vacuum cleaner to be shipped and stored in a smaller box, as well as allowing a user to store the vacuum cleaner in a smaller space.

The handle assembly 51 includes handle 53 to facilitate operation by a user, as shown in FIGS. 2 and 3. A power button 52 can be disposed on the handle assembly 51 to turn on and off the supply of power to the vacuum cleaner 11. The handle 53 is connected to a handle tube portion 54. The airflow deflector 41 is disposed at a free end of a connecting member 55 of the handle assembly 51 to deflect air into the nozzle 36 connected to the intake tube 31. The nozzle 36 is preferably unitarily formed as a single piece with the intake tube 31. An opening 56 in the connecting member 55 is aligned with the intake tube opening 32 to receive the fastener 34 to secure the handle assembly 51 to the intake tube 31. The connecting member 31 is received within the intake tube 31 when the handle assembly 51 is connected to the intake tube 31, as shown in FIG. 2.

The airflow deflector 41 is disposed within the intake tube 31 such that a deflection surface 43 of the airflow deflector 41 forms an angle β with a longitudinal axis 71 of the intake tube 31 passing through the deflection surface 43, as shown in FIGS. 7 and 8. The angle β is an “obtuse angle”, which term is used in its ordinary meansing of an angle that is greater than 90 but less than 180 degrees, to reduce turbulent airflow within the intake tube 31. Preferably, the angle β is between about 135 and about 150 degrees, inclusive. More preferably, the angle β is between about 140 and about 145 degrees, inclusive. The deflection surface 43 forms an angle θ with an inner surface 37 of the intake tube opposite the nozzle 36, as shown in FIGS. 7 and 8. The angle θ is an obtuse angle to reduce turbulent airflow within the intake tube 31. Preferably, the angle θ is between about 135 and about 150 degrees, inclusive. More preferably, the angle θ is between about 140 and about 145 degrees, inclusive. An interference fit is preferably formed between the airflow deflector 41 and the intake tube 31. A groove 83, as shown in FIG. 4, can be formed in the airflow deflector 41 to receive a gasket 81, as shown in FIGS. 2, 3 and 5, to further facilitate preventing airflow from passing the airflow deflector 41.

As shown in FIG. 5, the deflection surface has an angle α that is greater than zero degrees. Preferably, the angle α is between approximately 45 and 65 degrees, inclusive. The deflection surface 43 can be either a flat or curved surface. The deflection surface 43 has a radius R for a curved surface, which is preferably between approximately 3.75 and 5.50 inches, inclusive.

Alternatively, the handle assembly 51 can be integrally formed with the intake tube 31 as a one-piece assembly. The airflow deflector 41 is formed within the intake tube 31 during the manufacturing process such that the airflow deflector 41 is unitarily formed with the intake tube as a single piece.

Assembly and Operation

The handle assembly 51 is connected to the intake tube 31 by disposing the connecting member 55 in the intake tube 31 such that the connecting member opening 56 is aligned with the intake tube opening 32. A fastener 34 is passed through the upper cord hook 33 and through the connecting member opening 56 and the intake tube opening 32, thereby securing the handle assembly 51 to the intake tube 31. When the handle assembly is integrally formed with the intake tube as a one-piece assembly, such connection is not necessary.

The airflow deflector 41 is disposed within the intake tube 31 such that the deflection surface 43 forms an angle β that is an obtuse angle with respect to the longitudinal axis of the intake tube passing through the deflection surface, as shown in FIG. 2.

A partial vacuum is generated by the vacuum cleaner to cause air to be pushed into a base 61 of the vacuum cleaner 11. The intake tube 31 is connected to and in fluid communication with the base 61, such that the air flows up through the intake tube 31 as indicated by the arrows 14 in FIGS. 1 and 2. When the air reaches the end of the intake tube 13, the airflow deflector 41 directs the airflow into the nozzle 36. From the nozzle 36, the airflow goes to the debris collector, such as the vacuum bag 21, in the housing 15 as indicated by the arrow 20 in FIG. 1. Accordingly, the angle β of deflection surface 43 with respect to the longitudinal axis 71 of the intake tube 31 through the deflection surface being an obtuse angle reduces turbulence within the intake tube 31 to substantially maintain the suction of the vacuum cleaner 11. Accordingly, the effectiveness of the vacuum cleaner is maintained during use.

The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the scope of the present invention. The description of exemplary embodiments of the present invention is intended to be illustrative, and not to limit the scope of the present invention. Various modifications, alternatives and variations will be apparent to those of ordinary skill in the art, and are intended to fall within the scope of the invention as defined in the appended claims and their equivalents. 

What is claimed is:
 1. A vacuum cleaner, comprising: an intake tube through which air is passed; and an airflow deflector disposed in said intake tube having a deflection surface, said deflection surface being disposed at an obtuse angle with respect to a longitudinal axis of said intake tube passing through said deflection surface.
 2. The vacuum cleaner according to claim 1, wherein said angle is between about 135 and about 150 degrees, inclusive.
 3. The vacuum cleaner according to claim 1, wherein said angle is between about 140 and about 145 degrees, inclusive.
 4. The vacuum cleaner according to claim 1, wherein said deflection surface is generally concave.
 5. The vacuum cleaner according to claim 4, wherein a radius of said deflection surface is between about 3.75 and about 5.50 inches, inclusive.
 6. The vacuum cleaner according to claim 1, wherein a handle assembly is removably connected to said intake tube.
 7. The vacuum cleaner according to claim 6, wherein said deflection surface is disposed at an end of said handle assembly.
 8. A vacuum cleaner, comprising: an intake tube through which air is passed having an inner surface; an outlet nozzle connected to said intake tube; and an airflow deflector disposed in said intake tube having a deflection surface, said deflection surface being disposed at an obtuse angle with respect to an inner surface of said intake tube opposite said outlet nozzle.
 9. The vacuum cleaner according to claim 8, wherein said angle is between about 135 and about 150 degrees, inclusive.
 10. The vacuum cleaner according to claim 8, wherein said angle is between about 140 and about 145 degrees, inclusive.
 11. The vacuum cleaner according to claim 8, wherein said deflection surface is generally concave.
 12. The vacuum cleaner according to claim 11, wherein a radius of said deflection surface is between about 3.75 and about 5.50 inches, inclusive.
 13. The vacuum cleaner according to claim 8, wherein a handle assembly is removably connected to said intake tube.
 14. The vacuum cleaner according to claim 13, wherein said deflection surface is disposed at an end of said handle assembly.
 15. The vacuum cleaner according to claim 8, wherein said airflow deflector is unitarily formed as a one-piece member with said intake tube.
 16. A vacuum cleaner, comprising: a vacuum bag removably connected to said vacuum cleaner; an intake tube connected to and in fluid communication with said vacuum bag; a handle assembly removably connected to said intake tube; and an airflow deflector disposed in said intake tube having a deflection surface, said deflection surface being disposed at an obtuse angle with respect to a longitudinal axis of said intake tube passing through said deflection surface.
 17. The vacuum cleaner according to claim 16, wherein said angle is between about 135 and about 150 degrees, inclusive.
 18. The vacuum cleaner according to claim 16, wherein said angle is between about 140 and about 145 degrees, inclusive.
 19. The vacuum cleaner according to claim 16, wherein said deflection surface is generally concave.
 20. The vacuum cleaner according to claim 17, wherein a radius of said deflection surface is between approximately 3.75 and about 5.50 inches, inclusive. 